Global space based approach for strip-width-maximization machining of free-form surface

To improve the cutting efficiency for five-axis finish machining of free-form surface, a new approach to tool orientation optimization for strip-width-maximization machining based on global space is presented. Firstly, according to the character of the toroidal-end cutter, the global space is defined by a series of discrete points which may be gouged with the surface. Then the actual cutting profile is constructed with the cutting points those distances from the cutter are less than the calculating accuracy. Moreover, the effective machined strip width is accurately calculated. Finally, the tool orientation is optimized by maximizing the machined strip width based on the mapping between the tool orientation and the machined strip width. Example and experiment show that the length of the tool path of the new algorithm is reduced by 15.74% comparing with the second order approximation method at the same scallop height. It suggests that the cutting error can be controlled effectively and the proposed method is an effective way of improving machining efficiency for five-axis machining of free-form surface.